Brushless Screwdriver with Torque sensor

PGF-3000 / PGF-5000 / PGF-7000
Control Unit

PG-01
Instruction Manual(May 2019)

ET-A065 19A

Table of Contents
03 Safety Instructions
04 Check the Accessories
05 Switch to the Start Reading Mode
06 Connect the Cords
System Configuration of the Screwdriver
Check the Combination of the Screwdriver and thePower Supply
Installation Precautions
Turn on the Power
09 Change Power Supply Setting
10 Parts and Their Functions
PGF-3000/PGF-5000/PGF-7000
PG-01
PGF-SUBBOX14 Attach a Bit
Remove a Bit
Precautions when Using a Hexagonal Bit
15 Adjust Torque
Reference Table of Output Torque16 Activation and Stop of Screwdriver
Activate Screwdriver
Stop Screwdriver
Timing Chart of Screw Tightening
17 Set Learning Values (Teaching)
About Learning Values
18 Evaluation of Screw Tightening
OK/NG Judgment of Tightening Torque Value
Evaluation of Operation Time
Flowchart of Judgment
21 Screw Suction (Optional: Suction Attachment)
Configuration of PGFQ Type
Assemble the Attachments
Adjust the Under-head Length

Configuration of PGFR
Variations
Spring-type Mouthpiece
Reference Table of Suitable Screw Sizes
Assemble Attachment (PGF-5000)
Assemble Attachment (PGF-5000)
Clean the Mouthpiece

31 Connect to PC (USB)
Installation of Device Driver
Checking the Port
Data Output Format by Either RS-232C or USB
Connection
Output of Data for Judgment
Error-related Output
Measurement Judgment Output

PC Input
Hyper terminal (Example: Windows XP)
Data Taking-in Sheet (HIOS-PG-0611-V2-2_5)
Collection of Screwdriver Data (Application)

38 Troubleshooting
When a Problem Cannot Be Solved
40 Specifications
Specifications of PGF-3000/PGF-5000/PGF-7000
PGF-3000 External Dimension Drawing
PGF-5000 External Dimension Drawing
PGF-7000 External Dimension Drawing

Specifications of PG-01
External Dimension Drawing of PG-01

Specifications of PGF-SUBBOXExternal Dimension Drawing of PGF-SUBBOX

46 Maintenance and calibration (excluded fromwarranty)
46 China RoHS2 Table
47 Disclaimer

Safety Instructions
Please read this instruction manual carefully before use to ensure proper operation.
Installation◦Do not install this unit in the places listed below. It
may cause a fire or a malfunction.
・A place with high humidity or lots of dust
・A place that becomes too hot
・A place with naked flames◦Do not wear clothes with large cuffs, gloves, neckties
etc. They may get caught in the rotating screwdriverand cause an injury or malfunction.
◦Wear suitable clothing and protective eyewear forwork. Cover long hair with a hat etc., so that you canwork safely.

・A place exposed to direct sunlight◦Please contact our distributor if you cannot attach/remove a bit according to the instruction manual.

・A place with corrosive gas in the air

Maintenance・An unstable place

Power supply◦If you do not use this unit for a long time, turn off thepower and unplug the plug from the outlet for safety.

◦Be sure to install an earth leakage breaker and a safety
breaker to the commercial power supply to be used.

◦If you do not use this unit for a long time, remove theaccessories from it and store them in the packing box.

◦Do not connect anything other than specified parts tothe connection part of this unit.

◦Keep this unit in a place where appropriate
temperatures and humidity are controlled.

◦Do not damage the power cord or allow oil to touch it.
Also, do not place heavy objects on the power cord. It
may cause a fire.

◦Keep this unit in a place out of reach of people otherthan authorized workers.

◦When connecting/disconnecting the power cord or
screwdriver cord, etc., always hold the plug.

How to handle this unit
◦Do not disassemble or remodel this unit. It may cause
a malfunction.
◦Do not cause severe impacts or apply excessive force.
It may cause a malfunction.
◦Do not operate this unit with wet or oily hands.

◦Do not work with an unsteady posture or in an
unstable place.
◦Set an appropriate overtime period as the screw
tightening time and avoid situations where this unit
rotates continuously more than necessary.
◦If uneven rotations, abnormal noise, overheating,activation of the breaker, etc., occur during usage,
immediately stop using the screwdriver for repair.
However, overheating is possible due to usage
frequency and screw types. To prevent suchoverheating, get a spare screwdriver of the same unit
and use it alternately, or review the selection of thescrewdriver model.
◦Do not place an overload large enough to make theclutch unable to run out. It may cause the motor to
malfunction.
◦Do not touch the rotating screwdriver. It may cause an
injury or malfunction.
03

Check the Accessories
If anything is missing or damaged, please contact the dealer from whom you purchased this unit.

Control Unit

PGF-SUBBOX

8
4

6
2

Main Unit

PGF-SUBBOX

PG-01

Screwdriver Cord (3 m)

Cord for PGF-SUBBOX (40 cm)

AC Adaptor (1.5 m)

Start/Torque-up Cable (50 cm)

・RS-232C Cable (2 m)・Spare Fixing Inch Screws×4

I/O Flat Cable (30 cm)

USB / RS-232C Converter (35 cm)

Sensor Cord (3 m)

CD-ROM

Instruction Manual◦A USB cable is not included. Please procure it as necessary.
◦For “USB to RS-232 Adapter” Users
Driver CD for “USB to RS-232 Adapter” may not be included depending on time period. You can download the newest driverat ATEN website as needed.
http://www.aten.com/global/en/products/usb-&-thunderbolt/usb-converters/uc232a/

04

Switch to the Start Reading ModeNote:
The pulse start mode is set for this unit by default. Since its start mode is compatible only to the reading start, it isnecessary to change the start mode.

1 Unscrew the eight screws on the side of the power supply to remove the cover.

2 Turn off the switch (No. 2 of SW6) for reading/pulse located on the front side board
inside the cover.
◦Be careful that foreign matter does not enter inside while working.
Power supply: BLT-AY-61 / BLT-AY-71 Inside the cover

Reading / Pulse Select Switch
SW6

1 2
ON

3 Replace the cover after changing to the start mode.

05

Connect the Cords
Connect the cords included.
After connecting all the cords, start the power supply by inserting the plug into the outlet.

I/O Flat Cable
PLC

PGF
PG-01

RS-232C Cable
Connect to PC/PLC

Cord for PGF-SUBBOXPGF-SUBBOXPGF IN

7
3

PG-01 IN

PLC

95

Sensor Cord
Start/Torque-up Cable
Pin No.

Screwdriver Cord

PGF-SUBBOXPLC/BLTPower Supply: Front®

To the outlet

06

1

2

4

–

Black

FOR

–

GND

FINISHPower Supply: Rear
Power Cord

POWER

3

Blue Orange

PLC

■System Configuration of the Screwdriver
Note:
Since PLC needs to send a FOR signal separately to PGF-SUBBOX either from BLT-AY-61 or BLT-AY-71, do notsynchronize the FOR signals forcibly.
AC100-240V

BLT-AY
1 FINISH OUT

Start ofScrewdriver

2 COM
3 REV

IN

4 2WS

IN

5 RESET

IN

6 FOR

IN

External Sequence

PG-01
13 L.NG

OUT

14
15 GOOD OUT
16
17 H.NG OUT

12 COM(GND)
Screw Tightening(Z axis Descends)

Synchronize
with FINISH

1 FOR

AC100-240V

IN

1

2

3

4

2 T.UPIN

4 GRD
PG-F IN

PG-01 IN

SUBBOX

07

■Check the Combination of the Screwdriver and the Power Supply
Refer to the instruction manual for operating method of power supply.
ScrewdriverCompatible Power Supply

PGF-3000/PGF-5000

BLT-AY-61

PGF-7000

BLT-AY-71■Installation Precautions
Note:
Do not use this unit with a universal joint. If you use a universal joint or jig, etc., the actual torque may differ from thespecified torque.

■Turn on the Power
PG-01 automatically turns on when the AC adaptor is connected.
Note:
PG-01 performs automatic zero adjustment when the power is turned on. Do not apply a load to the tip of thescrewdriver or do not drive it during adjustment.

PG-01
AC Adaptor

To outlet

08

Power supply: Rear

ON

OFF

Change Power Supply Setting
For details of how to set up the power supply, refer to the instruction manual of the power supply.
Note:
As this unit does not support the setting of the torque up trigger and multiple impacts, please set the power supply
as described below.

1 Press and hold the

button.

◦The buzzer will sound twice in about two seconds after that. The setting mode will be enabled.
◦The LED for operation and the segment for setting value will be lit.

2 Use thebutton to select the setting for the number of forward rotation impacts

and the torque up trigger.

3 Use the/button to change the setting to <d1>.

◦Set HIGH and LOW respectively.
POWER
FOR

OPE

I

TUP

FIN

O

REV

ON

RES

2WS

OVT

FOR

OPE

TUP

FIN

REV

RES

2WS

OVT

OFF

MODE

ENT

MODE

ENT

DRIVER

Rotation: HIGH

4 Press and hold the

Rotation: LOW

button.

◦The buzzer will sound twice about two seconds after that. The setting mode will be disabled.
◦The LED for operation and the segment for setup value will turn off.

09

Parts and Their Functions■PGF-3000/PGF-5000/PGF-7000❶❷ ❸❹ ❺

❻

7
3
9
5
1

❼
❶Joint Shaft Collar
This is used when a bit is attached or removed.
❷Torque Adjustment Nut
This is to adjust the output torque.
❸Nut Fixing Ring
This is to prevent misalignment of the torque adjustment nut. It should be fitted closely to the torqueadjustment nut without a gap.
❹Torque Adjustment Scale
It indicates the reference value for adjustment of output torque. For details of torque value, refer to "Reference
Table of Output Torque" (P.15).
❺Flange
This is used to install the screwdriver to a fixing base.
❻Screwdriver Cord Connector
This is used to connect the screwdriver cord.
❼Sensor Cord Connector
This is used to connect the sensor cord.

10■PG-01
The measurement result of tightening a screw will be informed by the indicator and sound.
For setting of OK/NG judgment, refer to “"Set Learning Values (Teaching)" (P.17).

❶

❷

❸

Front

❹

❺

Control Unit

⓫

❿

❾

❽ ❼

❻

❶L.NG Indicator
This indicator is lit when the measured value is no good (smaller than the minimum pass value).
❷L.G Indicator
This indicator is lit when the measured value is good (larger than the minimum pass value and below theminimum learning value).
❸GOOD Indicator
This indicator is lit when the measured value is good (larger than the minimum learning value and smaller
than the maximum learning value).
❹H.G Indicator
This indicator is lit when the measured value is good (larger than the maximum learning value and below the
maximum pass value).
❺H.NG Indicator
This indicator is lit when the measured value is no good (larger than the maximum pass value).
❻Teaching Indicator
This indicator is lit when in the teaching mode (for setting of learning values).
❼Teaching Button
This is for setting to the teaching mode. Pressing and holding this button (2 seconds or longer) in the teachingmode will cancel the mode. For details of teaching, refer to "Set Learning Values (Teaching)" (P.17).
❽OPERATION OK Indicator
This indicator is lit while the screwdriver is rotating positively.
❾OPERATION NG Indicator◦This indicator is lit when the operation ends without torque up.
◦This blinks when the operation ends due to an abnormal measurement time.
❿Power Button
This is not used for this unit. When the AC adaptor is connected, power will be supplied automatically.
⓫Power Indicator
This indicator is lit when power is supplied.
11

⓬

⓭

Rear

⓰

⓯

⓮

⓬Connector for the PGF-SUBBOX Cord
The PGF-SUBBOX cord is connected here.
⓭I/O Connector
The I/O flat cable is connected here for the evaluation result to be output. The output format is an open
collector. Use this when you cannot connect with RS-232C.

19

1

20

2

Pin No.

Output signal

Description－

12

COM GND

13

L.NG (NG)

Output when the measurement value is NG (below the minimum pass value)

14

L.G (OK)

Output when the measurement value is OK (equal to or larger than the minimum
pass value and smaller than the minimum learning value)

15

GOOD (OK)

Output when the measurement value is OK (equal to or larger than the minimum
learning value and smaller than the maximum learning value)

16

H.G (Pass)

Output when the measurement value is good (equal to or larger than theminimum learning value and smaller than the maximum learning value)

17

H.NG (Fail)

Output when the measurement value is no good (larger than the maximum passvalue).

⓮USB PortA USB cable is connected here. No USB cable is provided with the unit. Procure one if necessary.
⓯RS-232C Connector
An RS-232C cable is connected here.
Pin assignment (the terminals not described are unused)
Pin No.

Signal name

I/O

2

RXD

OUT

3

TXD

IN

5

GND

⓰AC Adaptor Connector
An AC adaptor is connected here. Power will be automatically supplied when an AC adaptor is connected.

12

■PGF-SUBBOXRear

PGF IN

PG-01 IN

PLC

❶

❷

❸

❶Sensor Cord Connector
A sensor cord connector is connected here.
❷Connector for PGF-SUBBOX Cord
The PGF-SUBBOX cord is connected here.
❸Start/Torque up Cable Connector
A start/torque up cable is connected here.
Pin No.

1

2

3

4

PGF-SUBBOXBlue

Orange—Black

PLC/BLT-AY

FOR (START)FINISH (T.UP)

—

GND

13

Attach a Bit
Notes:◦Do not attach or remove a bit while the screwdriver is powered. It may cause an unexpected accident.
◦Use of a special bit may not fully demonstrate the original performance of PGF. Please contact us for details.

1 Insert a bit while pushing the joint shaft collar into the main unit.

7
3

9
5
1

2 Release the joint shaft collar and check if the bit is locked.
◦Pull the bit lightly and check if it will come out.

■Remove a Bit

1 Pull out a bit while pushing the joint shaft collar into the main unit.
■Precautions when Using a Hexagonal Bit◦No hexagonal bit is provided with this unit. Procure bits of any shape according to your requirement.
◦A double bit or a hexagonal bit with two grooves cannot be used.
Bit Drive

Shape

5HEX (WAF: 5mm)

6.35

5
14.0

14

1/4HEX (WAF: 6.35mm)

9.0

Adjust Torque
Note:
The "reference table of output torque" and the torque adjustment scale are approximate and do not guarantee
actual setting values.
For accurate torque check, please use an HIOS torque meter and Fidaptor.

1 If the torque is determined beforehand, turn the torque adjustment nut and nut
fixing ring referring to the "reference table of output torque".

◦Turn the torque adjustment nut clockwise to increase the torque and turn it counterclockwise to decrease thetorque.
◦Adjust it so that the end face of the nut fixing ring is right above the scale.

7
3

9
5
1

◦After the nut fixing ring is positioned, fit the torque adjustment nut accordingly.

7
3

9
5
1

2 Try to fasten a screw and check how it is fastened after the screwdriver stops andadjust the most appropriate torque.

■Reference Table of Output Torque
PGF-3000

PGF-5000

PGF-7000

Nm

Nm

Nm

0.55

1.2

2.8
2.6

0.5
1.0
0.4

0.8

0.3
0.2

2.2
1.8

0.6

1 2 3 4 5 6 7 8Torque Scale

0.4

1.4

1 2 3 4 5 6 7 8Torque Scale

1.0

1 2 3 4 5 6 7 8 9 10Torque Scale

15

Activation and Stop of Screwdriver
Note:
This unit is designed to be used eight hours a day (about 4,000 shots).

■Activate Screwdriver

1 Input a FOR signal to the power supply.
■Stop Screwdriver

1 Either turn off a FOR signal or input a RESET signal.
■Timing Chart of Screw Tightening
PLC Internal Sequence
Start Screw Tightening
To Screw Tightening POS
Screw Tightening
POS Memory
Screw Tightening Z-axis
Descent Command
Screw Tightening
Completion Memory
Screw Tightening Z-axis
Ascent Command
Screw Tightening Z-axis
Ascent Memory
Screw Tightening
Operation Completed

PLC❶

HIOS Product
BLT-AY-XX: FOR Signal(PLC➡BLT-AY-XX)
BLT-AY-XX: FINISH Signal(BLT-AY-XX➡PLC)
SUBBOX: FOR Signal(PLC➡SUBBOX)SUBBOX: T.UP Signal(PLC➡SUBBOX)

❷

❸
❹

❺

❻

❶PLC sends OFF signal 100ms after it receives FINISH signal from BLT.
❷PLC sends a signal 100ms later❸PLC sends ON signal to SUBBOX after it receives FINISH signal from BLT❹The torque in T.UP signal sent to SUBBOX is saved.
❺PLC sends OFF signal 100ms after it receives FINISH signal from BLT-AY-XX (the torque is sent from PG-01 to PLC within 100ms).
❻The screwdriver turns off when the Z-axis ascent sensor turns on (after a time lag of over 100ms).

16

Set Learning Values (Teaching)
Measure the "tightening torque" and "working time" by using screws and materials actually used to set thereference values for work. The two values recorded are the minimum and maximum, respectively.
Also, after teaching, it is possible to change the error tolerance of the learning values and the learned values in
the attached application or Excel file.
Note:
Teaching should be done under the same conditions as actual operation.
An error may occur in the measured value if the screw to be used, the materials to be fastened, the attaching methodof the screw, etc., are different from actual operation.

1 Press and hold the teaching button.
Control Unit

◦A buzzer sounds in about 2 seconds and the teaching mode is enabled.
◦The teaching indicator is lit.
◦L.NG indicator and H.NG indicator blinks.

2 Using the screws and materials to be actually used, perform tightening more than 3times.

◦Every time after tightening is completed, a buzzer sounds once, and the measured value is recorded.
◦The measured values of the third to tenth trials are recorded and the values after the eleventh trial will overwrite
the old values.

3 Press and hold the teaching button.
◦A buzzer sounds in about 2 seconds and the teaching mode ends.
◦The teaching indicator, L.NG indicator and H.NG indicator turn off.

■About Learning Values◦The learned values do not disappear even when the power is turned off.
◦To reset the learned values, perform teaching again. The previous learned values will be deleted when theteaching mode is enabled.
◦After purchasing, please perform teaching with PG-01 for the first time. Otherwise, it is not possible to set
learning values with the attached application.
17

Evaluation of Screw Tightening◦It measures actual screw tightening work in real time, compares the measurement with the learning value, andinforms the user of the evaluation result with a indicator and sound.
◦The reverse rotation of the screwdriver is not evaluated.
◦The allowable error range at the time of purchase is set to 10% for both upper and lower limits. If you want tochange it, please use the attached application.

■OK/NG Judgment of Tightening Torque Value
If no error is detected in the screw tightening work, one of L.G, GOOD or H.G indicator is lit and the buzzer sounds.
Allowable error range
Lower limit value

Allowable error range
Upper limit value

Threshold value

Learning
value

Threshold value

Fail/NG

Pass/OK

Fail/NG

If the torque is within the learning values, the GOOD indicator will be lit, and if it falls within the allowable error
range, either L.G or H.G indicator will be lit. Conversely, when the torque is less than the lower limit value, the L.
NG indicator will be lit, and when the torque exceeds the upper limit value, the H.NG indicator will be lit, whichmeans fail.

18

■Evaluation of Operation Time
◦The operation time from start of rotation to stop of the screwdriver is evaluated against the learning values.
◦The blinking and lighting of the OPERATION NG indicator will turn off when the START signal is entered again.

Control Unit

Main reasons why OPERATION NG indicator is lit◦No torque up signal is sent because of reasons like screwdriver idling.
Main reasons why OPERATION NG indicator blinks◦A torque up signal was not sent during the learning measurement period.
If it is not necessary to strictly measure the operation time, by using the application, change the setting value
so that the learning interval will become larger.
◦Continuous ON/OFF operations at the end of tightening (pushing the button twice or three times in a row)
Note:
There is a nonintervention time of 100mS for torque measurement and evaluation after the START signal is input.
Nonintervention time of 100mS

If the screwdriver output is given to a screw even after tightening, the value will be larger than the measuring value
and not the expected tightening value.
To perform proper screw tightening, please do not perform continuous operations.

19

■Flowchart of Judgment
Power ON
Select an operation

Set the judgment value (TEACHING)

Normal operations

Tightening (Start signal) ON

L.NG, and H.NG blinks
if no teaching value is set.

Set the evaluated value
TEACHING LED is lit (red)L.NG & H.NG LED blinks (red)The set value can bechanged later from thetabulation software on theconnected PC.

BLT-AY-61/71 FOR

LED OFF at completion

Initial resetting of PG-01

OPERATION OK LED ON (green)
One beep

End of tightening(Torque up signal)

No torque up signal
OPERATION NG LED ON (red)Evaluation

NG

OK

L.G, GOOD or H.G LED ON (green)
One beep
Signal output

End (Start signal: OFF)

20

L.NG LED or H.NG LED ON (red)If measurement time is NG, OPERATION NG LED blinks (red)Two beeps
Signal output

BLT-AY-61/71 T-UP

Screw Suction (Optional: Suction Attachment)
With the suction attachment (optional), it is possible to suck a screw to the bit end by using the negative pressureof the pump. There are two shapes of the suction attachment.
The pump to generate negative pressure is not provided with the unit. Please procure it by yourself or contact us.

■Configuration of PGFQ Type❶Suction attachment ASSY

❷Mouthpiece

❸Hose

Model

PGF-3000

❶P/N

❷Type

Φ7.5

PGFQ3-SETF3

PGF-5000

Compatible bit

Φ4, L80mm

Accessories❸Hose (L: 3.5m, I/D:
∅4, O/D: ∅7)18mm

PGFQ5-SET

Φ4, L80mm

Φ14
PGF-7000*

PGFQ7-SET

F6

31mm

Φ5, L100mm* If the socket of the bit is 1/4HEX, please contact us.

21

Assemble the Attachments

1 Attach a bit as required.
◦A bit longer than an ordinary one is preferable.

2 Attach the suction attachment.
◦Turn it counterclockwise.

3 Attach a mouthpiece.
◦Turn it clockwise.

4 Connect the hose.

22

Adjust the Under-head Length
It is possible to adjust the under-head length (margin) of a screw at the mouthpiece end.

1 Turn 🅐  and 🅑 counterclockwise at the same time to loosen them.
◦It becomes loose and the holder slides.

▶
Under-head

2 After length adjustment, turn 🅐 clockwise.
◦Fix (A) closely to the screwdriver unit.

23

■Configuration of PGFR
The special suction attachment PGFR with a long holder to be assembled to PGF-5000 and PGF-7000 (socket:
1/4HEX) is available. Before purchasing PGFR, it is necessary to check the sizes below: ❶ the suction attachment
ASSY, ❷ bit and ❸ spring-type mouthpiece. The accessories are all optional.
Notes:The bit (❷) is attached to the holder by turning it clockwise. So, if the screwdriver is used in the reverse rotation, thebit may become loose.
The hose is not provided with the unit. Please procure it by yourself or contact us.
The specifications of the hose: Φ4 (I/D) x Φ6 (O/D)

Hose❶Suction attachment ASSY

Mouthpiece holder
Bit holder❷Bit (screw type)❸Spring-type mouthpiece

Model

❶P/N

PGFR-5000

PGFR5-SA

PGFR-7000(1/4HEX)PGFR7-SA❷End shape (screw diameter, P/N); length; end diameter＋#1 (M2.0-M2.6, RBP4140S)＋#2 (M3.0-M5.0, RBP4240S)

40mm

Φ4

❸P/N
See "Spring-type Mouthpiece"(P.25).

Variations◦The standard length of the mouthpiece and its holder is 85L. There are other special options including 32L, 56L,
60L, 95L, 100L and 125L.
◦The mouthpiece with a deep hole comes in 41L and 61L in addition to the standard 27L.
*It may take some time for the delivery of the products with special specifications depending on inventory. Contact
us before placing an order.

24

Spring-type Mouthpiece
The spring-type mouthpiece has two variations: with a movable inner sleeve and a movable outer sleeve. Selectone according to your needs.

How to Read the Part No.

FS60-80J
1 2 3 45

6

1

Type: F3, F6

2

With a spring

3

Classification of screwdriver torque range

4

Movable sleeve: outer (0), inner (1)5

I/D (example: 80 stands for 8.0)

6Material and shape: J: Duracon, A: aluminum, S: stepped

Movement of the Inner Sleeve Type▶

When a screw and the bit are fitted by vacuum pressure, thesliding mouthpiece moves horizontally to keep the screw verticaland supports the screw head.

Sliding mouthpiece

P/N: FS61-68

P/N: FS61-74

P/N: FS61-68S

17.5
Φ9 Φ7.4

Φ5.6

Φ4

▶

▶

Φ8 Φ6.8▶
25

Movement of the Outer Sleeve Type
When a screw and the bit are fitted by vacuum pressure, thesliding mouthpiece moves horizontally to keep the screw verticaland supports the screw head. Since the diameter of themouthpiece is smaller than the outer diameter of a screw, it isgood for screw tightening in a tight space.

▶
Sliding mouthpiece

P/N: FS60-68J / FS60-68A

P/N: FS60-80J

17.4
7.6
Φ10

▶

Φ8

Φ8

Φ6.8

▶

Reference Table of Suitable Screw Sizes
Size

M2.6

Screw TypePGFR-5000
Model
PGFR-7000

Pan

Binding
FS61-68
FS61-68S

M3.0
Truss

Pan

Binding

FS61-68
FS61-68S

M4.0
Truss

Pan

FS60-68J
FS60-68A
FS61-68S
FS61-74

FS60-68J
FS60-68A
FS61-68S
FS61-74

Binding

Truss

–

–

FS60-80J

Special products to be able to hold small screws (less than 2.6mm) are available. Contact us for details. It may takesome time for the delivery of the products with special specifications depending on inventory. Contact us before
placing an order.

26

Assemble Attachment (PGF-5000)

1 Remove the bit attached to the screwdriver if required.
2 Attach the suction attachment.
◦Turn it counterclockwise.

3 Attach the bit to the mouthpiece holder.
◦Push the mouthpiece holder into the main unit.
◦Attach the bit to the bit holder by turning it clockwise.

▶

4 Attach the mouthpiece.
◦Turn it counterclockwise.

5 Connect the hose.

27

Assemble Attachment (PGF-5000)

1 Remove the bit attached to the screwdriver when necessary.
2 Remove the flange◦Turn it clockwise.

3 Remove the base from the suction attachment.
◦Turn it counterclockwise.

4 Attach the base from the attachment to the main unit.
◦Turn it counterclockwise.

5 Attach the flange.
◦Turn it counterclockwise.

28

6 Attach the suction attachment.
◦Turn it clockwise.

7 Attach the bit to the mouthpiece holder.
◦Push the holder into the main unit.
◦Attach the bit to the holder by turning it clockwise.

▶

8 Attach the mouthpiece.
◦Turn it counterclockwise.

9 Connect the hose.

29

Clean the Mouthpiece
Clean the mouthpiece regularly for safe use.

1 Remove the mouthpiece by holding the knurled part.
◦Turn it clockwise.

2 Dismantle it using a spanner of 7 mm across flats.
◦Turn it clockwise.

◦Be careful not to lose internal small parts.

3 Clean the mouthpiece.
4 Reassemble the mouthpiece to the original condition and check if the sliding
mouthpiece moves smoothly.

30

Connect to PC (USB)Make sure that PG-01 is powered on before connecting.

■Installation of Device Driver

1 Connect PG-01 to PC with a USB cable.
◦The wizard screen is displayed.

2 Select <Install from a list or a specific location> and click <Next>.

3 <Reference>, Select [USB-CDM 2.00.00] in the attached CD-ROM and click <OK> and<Next>.

◦Installation begins.

31

4 After installation is finished, click <Finish> on the wizard.

◦This ends the initial setting.

Note:
Depending on your environment, the installation screen may be displayed again. In that case, please follow the sameprocedure as above.

■Checking the PortThis step checks which port the USB is connected to.

1 Select [Start] menu, [Setting], [Control Panel] and [System].

2 Click [Hardware] tab and [Device Manager] to display the connection port by [Port(COM and LPT)].

USB in this case is [COM4].

32

■Data Output Format by Either RS-232C or USB Connection
Output of Data for Judgment
The data for judgment is output for each measurement in the three formats in the sequence below.
1 Measurement Data
D10 XXXX XXXXX <LF>
Measurement time – 5 digits (unit: mS)
Torque conversion value – 4 digits
2 Recorded Learning Value
D00 XXXX XXXX XXXXXXXXXXXXXX <LF>
Display maximum learning measurement time
Display learning maximum value
Display minimum learning measurement time
Display learning minimum value
Display learning number

3 Judgment reference values
D20 XX XXXX XXXX XXXXXXXXXX <LF>
Judgment measurement time maximum value
Judgment maximum value
Judgment measurement time minimum value
Judgment minimum value
Judgment error rate

Error-related Output
E90

End which cannot be detected by 0 areas, and judged[Zero area detection/Impossible
judgment ending]

E91

Abnormal termination at measurement time

[The abnormally end at themeasurement time]

E92

Study shortage and end which cannot be judged[The ending about which it is
impossible to judge by the learning
lack]

E93

Judgment=LOW NG[Judgment = Low NG]

E94

Judgment=HIGH NG[Judgment = High NG]

Measurement Judgment Output
E00

Judgment=GOOD[Judgment = Good]

E01

Judgment=LOW OK[Judgment = Low OK]

E02

Judgment=HIGH OK[Judgment = High OK]
33

■PC Input
Hyper terminal (Example: Windows XP)
After the PC is turned on and the version information is displayed, auto-zero correction is performed. The
following messages for debugging are displayed that are not directly related to measurement.
Ver3.04 2012/07/03[Zero Adj A/D=7C2 G=1EA F=200][Zero Adj A/D=806 G=1EB F=200][Zero Adj A/D=808 G=1EC F=200][Zero Adj A/D=803 G=1ED F=200][Zero Adjustment end A/D=7FF Gain=1ED]

Example of a Measurement OK Message
In general, messages are either operation check messages or measurement data.
[Job Num = 4]
S00
[Lever SW ON][Job Num = 6]
S02
[Torque UP ON]

Operation check message for debugging

D10026900668
D000005026903150033701891
D2002026303210033001928

Measurement data

M21[Judgment=LOW OK]
E01[Judgment end]

Operation check message for debugging

Abnormal Conditions
This displays the condition when judgment results are abnormal.
[Job Num = 4]
S00
[Lever SW ON][Job Num = 6]
S02
[Torque UP ON]

Operation check message for debugging

D10028600590
D000006009600010000101894
D2002140513090131201931

Measurement data

[Abnormal termination atmeasurement time]
E91

Operation check message for debugging

34

Data Taking-in Sheet (HIOS-PG-0611-V2-2_5)
By using the data taking-in sheet in the attached CD-ROM, you can check the OK/NG of screw tightening on the
PC or record the measurement data.
Notes:◦Enable macros.

◦Start settings after turning on PG-01 and connecting it to the PC.
◦When using USB, the PC may turn off PG-01 automatically in some cases. In that case, please disconnect andreconnect the screwdriver.
◦There is no reaction to the reverse rotation of the screwdriver.
◦If you want to take in two types of data, create two files (for example, test1.xls and test2.xls) in advance. Then, start
up two applications, and then open each file.
If you open files by double-clicking them in Windows Explorer, two files are opened in the same application andthe application cannot be used.

Operating Environment
The data taking-in sheet was confirmed to be effective in the following environments:
・Microsoft Windows XP
・Microsoft Excel 2003
If it is not functioning, select application type “screwdriver data collection”.
Please be aware that maintenance and support services are unavailable since this is sample software.

35

Configuration of the Screen

❶❷

❸

❹ ❺

⓬
⓫
❿

❻

❾
❼
❽
❶Connection confirmation window
The login information is displayed.
❷Disconnect button
This ends data import.
❸Connect button
This makes the data import standby. If the previous data is necessary, please save the current data first andthen connect the screwdriver. (The previous data will be cleared upon connection.)❹COM port
Check the port number and enter it. Then, press [Enter] on the keyboard. Usually, select COM as the port.
Cell colors
・Gray: the screwdriver is not connected.
・Yellow: the screwdriver is connected.
❺LAN settings
Optional❻Judge On/Off
Errors E90/E91/E92 can be turned ON/OFF.
ON: the measured values are entered in the datasheet.
OFF: the measured values are entered in the irregular sheet.
❼Measurement settings processing table
The table shows commands and settings processing that are displayed in the log.
❽JudgmentThis indicates OK/NG of screw tightening with colors.
❾Output data
Torque equivalent value: this indicates values taken during actual operation.
Measurement time: this indicates the time from screw tightening to torque-up.
Number of the learning: indicates the number of teaching operations performed.
36

Minimum of the learning: indicates the minimum teaching value (modifiable).
Maximum of the learning: indicates the maximum teaching value (modifiable).
Measurement time of minimum: indicates the teaching minimum time (modifiable).
Measurement time of maximum: indicates the teaching maximum time (modifiable).
After inputting a number, press [Enter] on the keyboard.
・These learning-related values will be sent to PG-01 by clicking the [Write learn-value] button after entering a
number.
・If the [Learned value change] button is not pressed, the memory in PG-01 won’t be updated and the previous
value will be recovered after the next torque-up operation.
❿Judgment comparison data
Torque value: indicates the value output on the graph sheet.
Judgment minimum value: indicates the amount minus the % setting for the learning minimum value.
Judgment maximum value: indicates the amount plus the % setting for the learning maximum value.
Meas. Time of judge minimum: indicates the amount of the time minus the % setting for the learning minimum
measurement time.
Meas. Time of judge maximum: indicates the amount of the time plus the % setting for the learning maximum
measurement time.
⓫Judgment error rate (%)
This sets the acceptable evaluation threshold before a screw tightening operation.
Selecting the judgment error rate while the screwdriver is connected transmits the selected rate to PG-01. Even
after disconnecting the PC, the selected rate will be retained.
The selectable rates: 0%, 2%, 5%, 10% or 20% (02=2%)⓬Work On
Normally this turns on automatically when an operation is performed.

Other Sheet

Data Sheet

Graph Sheet

Irregular Sheet

Collection of Screwdriver Data (Application)
The operation data is collected in the same way as the data taking-in sheet. The data is saved in the CSV format.
For details, click [Instructions] on the screen of screwdriver data collection.

37

Troubleshooting
If you have any problem while using this machine, please check the items in this section before making inquiries.
Then, if the problem persists, please contact your dealer or us.

The L.NG or H.NG indicator blinks when the power is turned on.
T here is a possibility that the learning values are not set correctly. Repeat teaching 3 times or more to set thelearning values.
➡"Set Learning Values (Teaching)" (P.17)

The L.NG or H.NG indicator flashes even when the teaching mode is ended andmeasurement cannot be performed.
There is a possibility that data for evaluation comparison is insufficient. If the learning count is less than 3, theindicator will keep flashing even if the teaching mode ends. Repeat teaching 3 times or more again to set thelearning values.
➡"Set Learning Values (Teaching)" (P.17)
In the following cases it is difficult to make an evaluation, and it may not be counted as learning.
・Torque value is 10 or less ("E90" [Zero area detection/Impossible judgment ending])
・Idling of the screwdriver occurs or the measurement time is 100 mS or shorter. ("S01" [Lever switch Off(notorque up)])Teaching or evaluation cannot be done properly.
 ake sure that the start mode of the power has been changed to the reading mode. Also, turn off power to checkM
if the cords are connected correctly and then turn on the power again.
➡"Switch to the Start Reading Mode" (P.05)➡"Connect the Cords" (P.06)

Setting cannot be changed from the tabulation software.
 lick the [Write learn-value] button after input of a number. The settings in PG-1 will be updated by clicking theC[Write learn-value] button.
➡"Data Taking-in Sheet (HIOS-PG-0611-V2-2_5)" (P.35)

The torque is abnormally low or high.
Make sure that the serial number of this machine is the same as that of PG-01/PGF-SUBBOX. Also, turn off thepower to check if the cords are connected correctly and then turn on the power again.
If the problem persists, replace the sensor cord.

38

■When a Problem Cannot Be Solved
When contacting us, have the following information ready:◦Product name (PGF-3000 / PGF-5000 / PGF-7000)◦Dealer where this machine was purchased◦Description of the problem (detailed description of the operation performed and its result, etc.)◦Serial number (on the label of the product)
R

Brushless® Driver
PGF - 5000

No.

No.
MADE IN JAPANMADE IN JAPANMade in Japan

Main Unit

PG-01

PGF-SUBBOX

39Specifications
The product specifications are subject to change without prior notice due to improvements of the product.
The external dimension drawings are not full-scale.

■Specifications of PGF-3000/PGF-5000/PGF-7000
PGF-3000

PGF-5000

PGF-7000N･m

0.2-0.55

0.4-1.2

1.0-2.8

Kgf･cm

(2-5.5)(4-12)(10-28)Model
Output Torque Range
Torque Switching
Unloaded Rotation
Speed (rpm) ±10%
Screw Size (mm)Bit Drive

Stepless Adjustment
HI (11 steps)

625-950

690-985645-935

LOW (11 steps)

115-325

115-320210-595

Machine Screw

1.7-2.3

2.3-3.0

2.6-5.0

Tapping Screw

2.0-2.3

2.0-2.3

2.6-4.0

HIOS ShankH4

H4

H5 and 5HEXHEX Shank－－

1/4HEX

Power supply
WeightDimensions

40

BLT-AY-61
363g

BLT-AY-71
494g

See the external dimension drawing

809g

Ø28

21.7

Ø21

52.5

M32P1.5 CCW thread(for ﬂange)

BIT=L80
102

79

Ø29

∅40

5.5

2-∅

101〜105

R5

38.7

6
4

148

Ø18

21.3

14.3

6.7

PGFQ-3000

Ø4+0.012
-0

Ø8.5
Ø23

2.4

M30P1.5
CCW thread

23.5

253〜257

PGF-3000 External Dimension Drawing
mm

PGF-3000

Ø43
Ø20

38.5

Ø40

Ø32

2

51

41

PGF-5000 External Dimension Drawing

mm

PGF-5000

PGFQ-5000

PGFR-5000+FS61-68

14.3

6.7

Ø20

Ø18

Ø43

179

37.5

4

4

280.5〜284.5

Ø40

Ø28
21.7

98.2

97.5〜101.5

Ø10
Ø26

Ø41
Ø29

BIT=L804

Ø4 +0.012
-0

74.5

18

48

35.9

M32P1.5 CCW thread

19

4

Ø34

Ø21

17

Ø8

∅40

196.3

122.8

61
51

17.5

27

85
87.4

2-∅5

.5

70

Ø18

R5

Ø8

42

87.5

70

Ø15

85.3

0

51
Ø12
15

120.3

49

washer t=1Ｘ2

428

305.3〜315.3

7

179
14.3

6.7

PGFQ-7000

17.5

∅4

122.8

61
BIT=L100

85.3

47.7

Ø38

washer t=1Ｘ2

Ø30
Ø32
24.5

160.6

Ø12

122.3〜132.3

4 +0.012
-0
4.9

23

M36P1.5 CCW thread

4

PGF-7000

27

5.5

R5

2-∅

PGF-7000 External Dimension Drawingmm

PGFR-7000+FS61-68

Ø20
17

Ø43

38.5

Ø40

Ø42

Ø36.2

Ø27

Ø8

43

■Specifications of PG-01
AC Adaptor

Input: AC100-240V (50-60Hz)
Output: DC12V

Weight513g

Dimensions

See the external dimension drawing

RS-232C
communication

Speed: 4800bps
Start bit: 1Bit
Stop bit: 1Bit
Data length: 8Bit
Data format: ASCII
Parity: none
Standard: RS-232C
Terminal: D-SUB 9 pins

PC

PG-01

Straight Cable

FemaleMaleTransmission Data
Transmission Register

Transmission Signal
Level Conversion

StatusControl Circuit

Received Signal

Reception Register

Received Data

Level Conversion

Example of Connections

Common to plus and minus
Output: sink typeI/O input output

External Dimension Drawing of PG-01

mm
118

120

20

44

φ

10

4.

10

2
L.NG
POWER

L.G

PG-01
GOOD
OK
NG
OPERATION

149

44

H.G

CONTROL UNIT
H.NG
TEACHING

49

2-

■Specifications of PGF-SUBBOXWeight391g

Dimensions

See the external dimension drawing

2.5

External Dimension Drawing of PGF-SUBBOX
149.0
118.0

10.0

35.0

10.0

35.0

PG-01 IN

BLT

44.0

PG-F IN
49.0mm

1青 FOR(START)
2橙 FINISH(T.UP)

3-4黒 GND

2-

φ

4.

2ｷ

ﾘ

1 青：Blue
2 橙：Orange
3 -4 黒：Black

136.0

45

Maintenance and Calibration (Excluded from Warranty)
Because transducer is installed in PGF, an overhaul or a calibration is recommended every 6 months. Please makesure to enclose PG-01 that has the same serial number as PGF when you ask for a maintenance.

China RoHS2 Table
If you are asked by China Customs, please show this table to them.
有害物质名称及含量标识格式
产品中有害物质的名称及含量
有害物質
部件名称

铅（pb）

汞（Hg)

镉（Cd)

六价铬
（CR(VI))

多溴联苯
（PBB）

多溴二苯醚
（PBDE）

电路板总成

×

○

○

○

○

○

电机单品

×

○

○

○

○

○

齿轮

×

○

○

○

○

○

外壳

○

○

○

○

○

○

螺丝刀线

×

○

○

○

○

○

电源适配器

×

○

○

○

○

○

本表格依据 SJ/T 11364 的规定编制。
○ ：表示该有害物质在该部件所有均质材料中的含量均在 GB/T 26572 规定的限量要求以下。
× ：表示该有害物质至少在该部件的某一均质材料中的含量超出 GB/T 26572 规定的限量要求。

In addition, the China RoHS marks also is required at the product and product box.
At the product, you can find it at the bottom and it is marked on the product box.
If you cannot find the mark, please ask your distributor.
In case of emergency, please cut the mark below and stick at the bottom of product and on the product box.
China RoHS mark

Note:
Minimum size of China RoHS mark is 5mm at outer diameter.

46

Disclaimer■Disclaimer
The information in this document is subject to change without notice.

■Trademarks
Microsoft, Windows, Windows XP, and Excel are trademarks or registered trademarks of Microsoft Corporation in
the United States and other countries.
Also, other company names and product names in this manual are trademarks or registered trademarks.

■Illustrations
Illustrations used in this manual are those for PGF-5000 unless otherwise noted. However, if models havedifferences, multiple illustrations are also displayed with the model names such as "PGF-XXXX / PGF-XXXX".

■Abbreviations
The following product names used in this manual are abbreviated.
Microsoft Windows XP operating system → Windows XP

47

HIOS Inc.
1-35-1 Oshiage, Sumida-ku Tokyo, Japan 131-0045
http://www.hios.com